Modular panels and system for using said panels

ABSTRACT

Construction panel and method for construction using said panel. Each construction panel comprises a lightweight structural element and insulation material sandwiched between a multilayer of lightweight boards which may have different types of finishing. The invention discloses an innovative system for rapid, more efficient and safer construction of building structures, resulting in lightweight yet resistant structures.

FIELD OF THE INVENTION

The present invention relates generally to a system of structural building materials and, more specifically, relates to a lightweight structural element, in the shape of a panel or tile, for building construction in not only interior wall spaces, but also exterior walls and facades, partitions and even slabs. The present invention provides a total weight and thickness reduction, while achieving high flexibility, wide varying temperature and natural element insulation and improved sound isolation.

BACKGROUND OF THE INVENTION

The rapid growth in many areas around the world driving the need for housing and other functional buildings has made it essential to employ modern methods and materials with the aim of accelerating construction rates, reducing weight of buildings and building materials, increasing life expectancy and strengthening buildings against earthquakes as well as other natural or unnatural violent hazards. Addressing these requires an innovative solution based on the use of modern methods and modem building materials which will result in reduced weight of buildings and building material, shorter construction time, and enhanced durability of building and building material, which all ultimately combine to reduce construction costs.

Currently, there are several types of materials and systems that are being used in construction. Most commonly used are stone, wood, bricks, concrete, metal, hollow concrete blocks and plaster but also other materials. To be more specific, these are materials used for outer walls or even slabs between floors. For the less rigid of frailer materials, there is a compensation on quantity used (thickness or volume) to bear increased weight as building floors increase.

One of the objectives in civil engineering is weight reduction (lightening) of structures and buildings. To achieve this objective, engineering has innovated and provided composite materials that are lightweight yet maintain high resistance.

For a person skilled in the art, it is well known that the lesser the weight of a structure, the lesser the energy absorbed from earthquakes, and thus the seismic effect of the earthquake on the building is reduced. In other words, reducing the weight of (lightening) a building means providing improved safety against earthquakes.

The use of traditional and old construction materials such as bricks and clay blocks and cement blocks not only increases the magnitude of the dead load of a building but also increases energy consumption thereby may be considered as a waste in energy. Moreover, a low erection speed and a high volume of building rubble arising from the use of such materials are among the other problems arising with the use of such traditional materials with environmental and economic impacts.

Furthermore, as the weight of a building increases, the cost of the building structure increases thereby leading to a rise in the cost of the building. These issues can be considered as part of the numerous problems faced by the construction field.

Many construction materials are available individually for assembly at the construction site, while others are assembled as pre-fabricated in a production factory, then transported to the site to be erected. Further machine work or modifications is often required on site on these pre-fabricated elements to customize them to the needs of the architectural designs to allow for mechanical, electrical and plumbing (MEP). The current invention attends to that matter by allowing flexible material arriving on site with pre-set and pre-defined MEP.

Furthermore, there are a number of problems associated with the construction of multi-story buildings using the traditional construction techniques of Poured Concrete frame buildings, Pre-Cast Concrete frame buildings, Structural Steel frame buildings, Wood Frame buildings and Masonry construction. Multi-story buildings constructed with these construction techniques are built in the traditional manner of field craftsmen applying construction materials to first fabricate the frame of the multi-story dwelling on a foundation at the building site according to a set of architectural plans. While these methods of construction have worked for many years, there are inherent inefficiencies in these methods that result in significant time, cost, and quality penalties. The current invention is time and cost efficient since it provides ready to install and anchor panels with comparative or better performance (isolation, insulation, finishing, etc.)

Traditional construction techniques involve a lengthy process and, therefore, result in construction activity for an extended period of time. In addition, the finishing work may only be accomplished after the structural work is completed. Combined, these activities create both a financial burden as well as extensive labor and man-hour cost. In order to be time efficient, the current invention cuts down on time and spend less time on preparing ready-made panels.

This in-situ fabrication may result in poorer quality, is prone to an increase in errors and in particular human error, and requires the workers to innovate with respect to the interconnection of utilities, thereby resulting in inconsistency in implementation. The current invention, while being time efficient by having the MEP first fix ready by the time of the erection of the panels, also provides standardized and normalized MEP

In summary, for all of the above mentioned situations and scenarios, the process of construction ends up being time consuming and requires significant manpower resulting in both an inefficient and costly process.

While the concept of prefabricated panels and even methods of using these in the construction field have been disclosed as described herein below in the cited prior art, and as will be demonstrated in the present disclosure, a number of deficiencies still restrict the implementation of an efficacious construction system addressing simultaneously quality, time and cost.

In what is considered the closest prior art, WO2019239435A1 discloses a prefabricated polyethylene sandwich block and panel, however, it is used only for indoor partitions.

Document CN108867937A discloses precast concrete band ribbed sandwich panels arranged in juxtaposition. Despite this fact, the connection between two panel units should be a reinforced bar.

Document CN102168471B, although it discloses a composite board, the invention is limited to the boards being made of stainless steel only.

Document US20090205277A1 discloses a construction panel made of two core boards sandwiching the insulation material. Although these panels are more flexible concerning the dimensions, they do not resist to a high seismic load.

Document U.S. Pat. No. 7,770,354B2 discloses a lightweight cementitious panel that may be reinforced with wood fiber. However, these panels are limited in dimensions and use.

Document WO2017146837A1 discloses a method for building a multi-story building using the stacked wall truss construction method. Although this invention assures a stability without stacking columns, the system is more complicated than the traditional structural steel system.

The new construction systems have been proposed, including SIPS (Structural insulated panel system) and CIFS (concrete insulated form system) to address some of these concerns. None of these newer systems, however, comprise a pre-assembled construction panel system capable of effectively competing in terms of cost, assembly time, and skilled labor requirements with present widespread construction methods.

Hence, current construction techniques fail to deliver the quality and speed of construction that is desirable. In many locations, these impediments result in a severe shortage of multistory buildings and a commensurate lack of available quality buildings.

BRIEF SUMMARY OF THE INVENTION

Accordingly, it is therefore an object of the invention to provide a lightweight modular multi-functional panel designed for use in a system resulting in total control of weight and thickness, while achieving high bending stiffness, durability, and modularity. The system of the present invention may be adapted for use as internal partition walls, external or façade walls and slabs.

Furthermore, the flexibility and adaptability of the system of the invention allows for the use of the panels as wall bearing structures and beams for carrying the vertical and lateral loads of the structure.

In order to achieve all of these functions yet address the many advantages of cost, time and ecological benefits, the innovative system consists of a combination of anchoring structural elements, vertical structural elements such as struts, and the use of pre-assembled or pre-fabricated wall panels that can constitute an auto formwork for the columns, pillars and peripheral beams. The panels are modular, factory pre-assembled, insulated, having an autoclaved high density cement board internal and external facia that can receive any type of finishing or that can be of stone or wood patterns, mass colored.

Accordingly, the current invention addresses all of the defects currently facing the construction industry by providing a construction method which uses structural skeleton elements along with modular, ready to install walls or panels comprising all the required electromechanical elements (MEP) as well as other requirements described and defined in the architectural design plans.

The modular panels are manufactured and delivered to a construction site pre-labeled for further rapid installation in their correct position and location, thus improving the efficiency in the construction work flow and ensuring correct and accurate placement of all of the MEP elements.

The present invention is more specifically described in the following paragraphs by reference to the drawings attached herein below only by way of example.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention will be better understood from a reading of examples of embodiments, taken in conjunction with the accompanying figures in the drawings in which:

FIG. 1 illustrates a front and partially exploded isometric view of a construction panel system.

FIG. 2 shows a concrete foundation and its preparation.

FIG. 3 illustrates the building method of a traditional concrete foundation.

FIG. 4 shows the panel to floor detail.

FIG. 5 shows a 3D view of the erected floor.

FIG. 6 shows the installation of the MEP works on the panels.

FIG. 7 shows an example of linking two panels.

FIG. 8 illustrates a wall opening done using the panels.

DETAILED DESCRIPTION OF THE INVENTION

As disclosed above, the innovative system consists of a combination of structural steel construction and the use of pre-assembled wall panels that can constitute an auto formwork for the columns, pillars and peripheral beams. The panels are modular, factory pre-assembled, insulated, having an autoclaved high density cement board internal and external facia that can be finished with any type of finishing or that can be of stone or wood patterns, mass colored.

For simplicity and clarity of illustration, the drawing figures illustrate the general manner of construction, and descriptions and details of well-known features and techniques may be omitted to avoid unnecessarily obscuring the invention.

In one embodiment, a construction panel system comprises one or more modules. Each module or panel 100 comprises a lightweight structural element 101 and insulation material 102 sandwiched between a multilayer of lightweight boards 103 as shown clearly in FIG. 1 .

In a preferred embodiment, the lightweight boards 103 are made of cement, cementitious fiber or any other acceptable such material currently in use or may become available for use in such conditions.

In another embodiment, the finishing surfaces can be plain or textured such as wood finishing, cement, PV panels, stone cladding among others.

In one embodiment, the lightweight structural element 101 can be made of steel, stainless steel, aluminum or any other metal or even material which provides similar characteristics for providing the desired structural features.

In one embodiment, additional layers of insulation 102 may be coupled to the lightweight structural element 101 from each side of the element to meet the architectural design or construction requirement. The insulation 102 layers may comprise one or more types of insulation material such as, but not limited to, foam, mineral wool and fiberglass among others. Alternative thicknesses and densities for insulation layers may be varied to achieve specific R-values for insulation. The different insulation layers may be used to also achieve sound or acoustic insulation which is achieved through the use of materials which reduce vibrations along the panels.

In one embodiment, a fire retardant insulation layer may be added to the system. Furthermore, a fire retardant paint layer may be applied to meet the requirement of the fire zoning.

In a preferred embodiment, the multilayer lightweight panels are water proof and water-resistant. They are unaffected by water and humidity, and may resist the impact of water under critical weather conditions.

In another embodiment, the panels 100 may be labeled during the fabrication process. Said labels may include information such as indications on the location, position, and level where said panel 100 is to be installed on site. Said labeling comprises the use of QR coding, bar coding, RFIDs or any other currently existing technology and technology which may be developed in the future and is compatible with the present invention.

In a preferred embodiment, the dimensions of the panels 100 may be variable in order to meet the needs of the project under construction, the structural element being reinforced to go beyond the restrictions in the dimensions of traditional wall panels.

In one embodiment, the panels 100 may also be used as siding panel or façade panels. In another embodiment, the panels 100 may be used as roof panels. In yet another embodiment, the panels 100 may be used as floor slabs.

In a preferred embodiment, the skeleton of the building may be a traditional structural steel. In such a preferred system, first the support structures used to support the structural steel body are erected, the support structures are typically formed from steel columns, beams or trusses, or from reinforced concrete. The next step would be erecting a series of vertically oriented steel elements spaced apart as needed or required to define a general shape of the building, floor or space as shown in FIG. 2 .

In one embodiment, the skeleton of the building may be made of reinforced concrete or any other acceptable construction material deemed to be able to bear the required load. First, all the support columns, beams and trusses are erected. the next step would be erecting a series of vertically oriented elements made of reinforced concrete or any other acceptable construction material.

In a preferred embodiment, as shown in FIG. 3 , the panels 100 are laid on a concrete base slab. After being poured, the concrete base is prepared with marking the boundaries and the panels positions. The structural steel building body is then erected. The panels 100 are then placed in position. After disposing the panels, these are fitted and aligned to ensure straight and flat surfaces. Alternatively, the panels are may be fitted and positioned at any preferred angle to obtain the shape and style required based on architectural drawings or design.

In one embodiment, the panels 100 are fixed to the floor and upper slab using bolts fastened into U channels already laid in the concrete as shown in FIG. 4 . While the use of U channels may be a preferred embodiment of the present invention and as shown here merely for the purpose of description, other means that U channels may be used to secure the panels solidly in place.

In a preferred embodiment, the gaps and joints between the panels are filled using mesh tape followed by cement mortar. Not to limit this step to the use of mesh tape and cement mortar, the gaps and joints may be filled and sealed as needed with any currently existing material available for use or may become available and which may provide similar characteristics to those desired form the use of mesh and mortar.

In one embodiment, the panels 100 and the skeleton body would form a complete floor as shown on FIG. 5 . The structural integrity formed by the skeleton of the building and the lightweight structural element of the panels can withstand seismic loads and offers better behavior than traditional construction due to its lightweight characteristics and fixation details. The system would meet earthquake resistance requirements taking into account wind and seismic lateral forces applied. Design based on minimum peak ground acceleration 2.5 m/sec2 (or as per project location requirement), in compliance with ACI318, IBC and UBC 97 standards. All of this resulting in less human and material damage and abiding by the highest standards of safety and security.

In a preferred embodiment, the formwork may be used for the columns and a beam may be made from the panels 100. The traditional formwork would not be needed and a finishing level would be obtained in the early stages of construction, cutting down on both cost and time.

In another embodiment, the panels 100 may be overlapping and are linked together using different techniques like zinc self-tapping screws as shown in FIG. 7 . For the purposes of illustrations, this is used as an example however, this in no way limits the use of other systems or techniques for linking together the overlapping panels.

In a preferred embodiment, as shown in FIG. 6 , the panels 100 are fabricated with surface and/or internal grooves and/or linkage spots to fit the first fix of all MEP works, such as electrical conduits, electrical boxes, water, gas and drainage pipes and all frames related to the plumbing fixtures.

Going forward, FIG. 8 illustrates different elements aligned to assemble a wall-opening. Wall-opening structure can be used to create an opening that can be used, for example, to attach windows to construction panel system.

The wall-opening structure may comprise construction panels 801, 802, 803, and 804, similar to the construction panel shown in FIG. 1 . In the embodiment of FIG. 8 , construction panels 801 and 802 are larger than construction panels 803 and 804 and such difference in size allows the opening to be formed when construction panels 801, 802, 803 and 804 are coupled together. The dimensions, height, length and width of said panels in the present disclosure may all be pre-fabricated and labeled for rapid and accurate fitting so as to maximize construction speed accurately and without human error or confusion.

In one embodiment, in case of design changes, the installed panels may be easily dismantled, removed and replaced with newly fabricated and labelled ones.

Although the invention has been described with reference to specific examples, it will be appreciated by those skilled in the art that the invention may be embodied in many other forms. It should also be understood that the various aspects and embodiments of the invention as described can be implemented either independently, or in conjunction with all viable permutations and combinations of other aspects and embodiments. All such permutations and combinations should be regarded as having been herein disclosed. 

1. A modular construction system comprising: a plurality of structural elements, a plurality of pre-fabricated panels, comprising a plurality of lightweight boards and insulation; wherein said panels comprise a plurality of pre-fitted mechanical, electrical and plumbing (MEP) first fix and a label.
 2. The system according to claim 1, wherein said structural elements comprise U-channels, C-channels, struts and beams.
 3. The system according to claim 1, wherein said plurality of panels further comprise lightweight structural elements.
 4. The system according to claim 1, wherein said label may be a barcode label.
 5. The system according to claim 4, wherein said barcode label comprises information on project, site, location, position, orientation, dimensions, dates and composition of said panel.
 6. The system according to claim 1 for use in construction of internal walls, external walls, load bearing walls and slabs.
 7. The system according to claim 1, wherein said panels may be used vertically, horizontally or at any angle in between.
 8. The system according to claim 1, wherein the structural elements and the panel composition are prepared according to building codes to withstand required seismic movement, weather conditions, fire, floods and load bearing.
 9. A method for building a multi-story structure comprising the steps of: a. preparing a floor slab, b. preparing lightweight modular panels which comprise a plurality of lightweight boards and insulation, wherein said panels comprise a plurality of pre-fitted mechanical, electrical and plumbing (MEP) first fix and a label, c. assembling a structural building skeleton, d. fixing labeled lightweight modular panels according to the information contained on said label, wherein said label may be a barcode label which comprises information on project, site, location, position, orientation, dimensions, dates and composition of said panel, e. filling and sealing gaps between said panels and between said panels and floor, f. pouring or making ceiling slab, g. filling and sealing gaps between said panels and said ceiling slab, and h. applying finishing on said panels.
 10. The method according to claim 8, wherein preparing said floor slab comprises marking the boundaries and positions of said panels.
 11. The method according to claim 8, wherein the steps of a. to h. are repeated for each floor. 